Square end mills are the kind of cutting tools you often see in the workshop, used to flatten things, make grooves or create contours. Because it has a flat bottom, when you use it to cut, it can not only be accurate, but also make the surface look particularly smooth. In order to give full play to its performance and extend its service life, correct usage skills are essential. This article will introduce the tips for using square end mills in detail to help users improve processing efficiency and quality in actual operations.

1. Selection of cutting parameters

1.1 Cutting speed

The cutting speed is crucial to machining and affects the tool life and processing effect. The speed needs to be adjusted when using different tools and materials: high-speed steel tools should be slow, and carbide tools can be fast. For example, it is recommended to cut aluminum at 300 to 600 meters/minute; while cutting steel should be reduced to 60 to 180 meters/minute.

1.2 Feed speed

The feed speed is very important. It is directly related to whether the surface we process is beautiful and how long the tool can be used. When choosing a feed rate, you need to consider how rough the tool is, how hard the material is, and how deep you want to cut. If you choose too high, the tool will wear quickly; if you choose too low, the efficiency will not be improved. Usually, the recommended speed is 0.02 to 0.1 mm per tooth, which is a suitable range.

1.3 Cutting depth

The cutting depth should consider the material and tool diameter. Shallow cutting prolongs tool life and increases processing time; deep cutting improves efficiency but easily damages the tool. The recommended cutting depth for roughing is 1/2-2/3 of the tool diameter, and 1/3-1/2 for finishing.

2. Cooling and lubrication

2.1 Selection of coolant

Using coolant during processing can help us lower the cutting temperature and prevent the tool from wearing so quickly. Take the square end mill as an example. Water-based or oil-based can be used, but it depends on what material we are cutting and how the process is to choose the most suitable coolant.

2.2 Importance of lubrication

Lubrication not only reduces friction, but also improves the quality of the machined surface. The right amount of lubricant can form a protective film between the tool and the workpiece, reducing direct contact and thus extending the tool life. Lubrication is particularly important for difficult-to-process materials such as stainless steel and titanium alloys.

3. Use tools properly

3.1 Avoid overloading

Overloading is like asking your knife to cut stone instead of butter. Not only will the tool be scrapped quickly, but your work material may also be deformed and may even damage your machine tool. Therefore, you have to choose the appropriate cutting parameters based on the capabilities of your machine tool and how "hard" it is, and don't let it do things beyond its capabilities.

3.2 Segmented processing

For the processing of deep grooves and complex shapes, it is recommended to use segmented processing methods and cut step by step. This can effectively reduce the tool load and avoid cutting too much material at one time, causing the tool to break or break.

3.3 Replace tools in time

When you notice that your tools are starting to wear, break, or have poor cutting effects, this is a clear signal that it is time to replace them. Ignoring this signal and insisting on using these worn-out tools will not only lead to a significant reduction in processing quality, but may also cause more serious problems and losses.

4. Tool maintenance and care

4.1 Regular cleaning

After each processing, the chips and residues on the tool should be cleaned in time. You can use a special chip cleaning tool or compressed air to clean and keep the tool clean and sharp.

4.2 Storage and management

The tool should be stored in a dry, clean, vibration-free environment. It is best to use a special tool storage box or tool holder to avoid damage caused by collision between tools. When storing, avoid direct sunlight and high temperature environment to prevent changes in tool material properties.

4.3 Regular inspection and grinding

Always check whether your tool is worn out. If there is a problem, repair it quickly. Remember to find a professional to do it, so as to ensure that the tool parameters are accurate and well repaired. Also, don't repair it too often, otherwise the tool may not be so easy to use.

5. Choose the right tool

5.1 Choose according to the processing material

Different materials have different requirements for tools. You should choose the right tool according to the specific processing material. For example, carbide tools can be selected when processing aluminum, and high-speed steel tools can be selected when processing steel.

5.2 Selection according to processing requirements

The appropriate tool specifications and types should be selected according to specific processing requirements. For example, a standard square end mill can be selected for plane processing, and a long-shank square end mill can be selected for deep groove processing.

5.3 Consider tool coating

Tool coating can improve the wear resistance and heat resistance of the tool and extend the tool life. Common coatings include TiN (titanium nitride), TiAlN (titanium aluminum nitride), etc. The appropriate coating type should be selected according to the specific processing conditions.

Conclusion

As an important cutting tool, the use skills of square end mills are directly related to processing quality and production efficiency. By reasonably selecting cutting parameters, correctly using cooling and lubrication, and reasonably using and maintaining tools, the performance of square end mills can be fully utilized and their service life can be extended. I hope that the introduction of this article can provide useful reference for the majority of mechanical processing practitioners and help the smooth progress of production and processing.